Apparatus for reducing fabric dimpling in electronic devices and associated methods

ABSTRACT

The present document describes an apparatus for reducing fabric dimpling in electronic devices and associated methods. The apparatus is used during assembly to prevent fabric, which is stretched over a perforated part (e.g., speaker housing), from dimpling into the holes (e.g., perforations) of the perforated part. The apparatus includes protrusions (e.g., pins), which act as a negative of the holes in the perforated part, to support the fabric as it is stretched over the perforated part. In particular, the protrusions are inserted through the perforations via an interior surface of the perforated part such that the protrusions are “proud” (slightly projecting from a surface) with respect to an exterior surface of the perforated part. The proudness of the protrusions may vary based on a degree of curvature of the perforated part at a location corresponding to a respective protrusion.

Many devices, including speakers, may be wrapped in fabric foraesthetics and hiding various features, such as holes. However, whenwrapping fabric around such devices, the fabric may sag into the holes.This sagging creates dimples in the fabric, resulting in a “golf balleffect” on the fabric and causing the holes to be visibly prominent.

One solution is to change the diameter of the holes (e.g., smaller holesresult in less dimpling of the fabric). For a speaker, however, thenumber of holes and the amount of open area in the speaker housing maybe designed to enable the maximum amount of audio output for thespeaker, so as to avoid “choking” the speaker driver output. Therefore,reducing the number of holes or the amount of open area may degrade thequality of the audio output of the speaker. Further, modifying the holesand open area fails to solve the dimpling effect in existing products.

Some conventional solutions may attempt to hide the dimples. Forexample, many traditional speaker products use black and/or thick fabricto attempt to hide the holes, but the holes often remain easilynoticeable. Other traditional speaker products may add noise to thecolor of the fabric to “trick” the user's eye into not seeing thedimpling. For example, some fabrics may have mélange, which is a medleyof light and dark colors (e.g., noise). The mélange adds color noise tothe fabric to reduce the visibility of the dimpling. Less mélange (e.g.,lighter and more uniform color), however, can result inmore-visibly-prominent dimples. Accordingly, finding a solution forexisting products with lighter and more uniform colors is challenging.

SUMMARY

The present document describes an apparatus for reducing fabric dimplingin electronic devices and associated methods. The apparatus is usedduring assembly to prevent fabric, which is stretched over a perforatedpart (e.g., speaker housing), from dimpling into the holes (e.g.,perforations) of the perforated part. The apparatus includes protrusions(e.g., pins, rods, cylinders), which extend outwardly from a surface ofthe apparatus and act as a negative of the holes in the perforated part,to support the fabric as it is stretched over the perforated part. Inparticular, the protrusions are inserted through the perforations via aninterior surface of the perforated part such that the protrusions are“proud” (slightly projecting from a surface) with respect to an exteriorsurface of the perforated part. The proudness of the protrusions mayvary based on a degree of curvature of the perforated part at a locationcorresponding to a respective protrusion.

In aspects, the apparatus is a support device (e.g., fixture) used inmanufacturing to secure and support a part (e.g., a housing component)in a particular position and orientation, ensuring that a plurality ofparts produced using the fixture maintain conformity andinterchangeability. Accordingly, the apparatus may also be referred toas a positioning fixture.

In some aspects, a method for reducing fabric dimpling is disclosed. Themethod includes assembling a perforated housing component onto anapparatus including a plurality of protrusions configured to be insertedinto a plurality of holes in an interior surface of the perforatedhousing component and to extend past an exterior surface of theperforated housing component. A predefined distance of a respectiveprotrusion defined may be based on a degree of curvature of the exteriorsurface of the perforated housing component within a region of theexterior surface of the perforated housing component corresponding tothe respective protrusion. In addition, the method includes, subsequentto the perforated housing component being assembled onto the apparatus,stretching fabric over the exterior surface of the perforated housingcomponent and the plurality of protrusions projecting from the exteriorsurface of the perforated housing component. The method also includesbonding the stretched fabric to the housing component and removing thehousing component from the apparatus.

In other aspects, an apparatus configured to prevent fabric dimpling infabric that is stretched over a perforated housing component isdisclosed. The apparatus includes a body and a plurality of protrusions.The body has an outer surface and is configured to support theperforated housing component for assembly of the fabric onto an exteriorsurface of the perforated housing component. The plurality ofprotrusions longitudinally extend from the outer surface of the body ina first direction that is substantially parallel to a second directionin which the fabric is to be stretched over the perforated housingcomponent. In addition, the plurality of protrusions are configured tobe inserted into a plurality of holes in the interior surface of theperforated housing component and project past the exterior surface ofthe perforated housing component to support the fabric as the fabric isstretched over the perforated housing component. A respective protrusionof the plurality of protrusions may have a longitudinal lengthsufficient to project past the exterior surface of the perforatedhousing component by a predefined distance that is defined based on adegree of curvature of the exterior surface of the perforated housingcomponent within a region of the exterior surface of the perforatedhousing component corresponding to the respective protrusion.

This summary is provided to introduce simplified concepts of anapparatus for reducing fabric dimpling in electronic devices andassociated methods, which is further described below in the DetailedDescription. This summary is not intended to identify essential featuresof the claimed subject matter, nor is it intended for use in determiningthe scope of the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

The details of one or more aspects of an apparatus for reducing fabricdimpling in electronic devices and associated methods are described inthis document with reference to the following drawings. The same numbersare used throughout the drawings to reference like features andcomponents.

FIG. 1 illustrates an example assembly mechanism in which an apparatusfor reducing fabric dimpling in electronic devices and associatedmethods may be implemented.

FIG. 2A illustrates an example of the apparatus from FIG. 1.

FIG. 2B illustrates an example of the housing component from FIG. 1seated onto the apparatus from FIG. 1.

FIG. 3 illustrates an example of proudness variation in the apparatusfrom FIG. 1 when the housing component from FIG. 1 is assembled orseated onto the apparatus.

FIG. 4 illustrates a section view of an example implementation of theassembly mechanism from FIG. 1, where the heating element is placed ontothe fabric, which is stretched over the housing component seated on theapparatus.

FIG. 5 depicts a method of reducing fabric dimpling in electronicdevices, in particular speaker housings and associated apparatuses.

FIG. 6 illustrates example devices for which the apparatus for reducingfabric dimpling can be implemented.

DETAILED DESCRIPTION

This document describes an apparatus for reducing fabric dimpling inelectronic devices and associated methods. The apparatus is formed as asubstantial negative of a perforated part (e.g., housing component) toenable the perforated part to be mounted to the apparatus. The apparatusincludes a plurality of protrusions (e.g., pins), which extend outwardlyfrom a surface of the apparatus and are configured to be insertedthrough the holes in the perforated part, via an interior surface of theperforated part. The protrusions extend past an exterior surface of theperforated part by a small distance (e.g., less than 0.2 millimeters(mm)) In this way, the protrusions are proud relative to the exteriorsurface of the perforated part and support the fabric as it is stretchedover the perforated part. Supporting the fabric during the stretching ofthe fabric over the perforated part reduces or prevents the fabric fromsagging into the holes and creating dimples.

The proudness (amount of projection from a surface) of the protrusionscorrelates to the curvature of the perforated part such that theproudness may vary based on a degree of curvature of the perforated partat a location corresponding to a respective protrusion. For example,protrusions may have a greater proudness (e.g., between approximately0.1 mm and approximately 0.25 mm) relative to the perforated part inregions having a greater degree of curvature and may have less proudness(e.g., between 0.04 mm and approximately 0.1 mm) in regions having alesser degree of curvature. Where the curvature of the perforated partis approximately zero (e.g., substantially flat region), the protrusionsmay be substantially flush with the exterior surface of the perforatedpart (e.g., the proudness of the protrusions may be approximately 0.0mm).

While features and concepts of the described apparatus for reducingfabric dimpling in electronic devices and associated methods can beimplemented in any number of different environments, aspects aredescribed in the context of the following examples.

FIG. 1 illustrates an example assembly mechanism 100 in which anapparatus for reducing fabric dimpling in electronic devices andassociated methods may be implemented. The assembly mechanism 100includes a positioning fixture (e.g., apparatus 102), a fabric press104, and a heating element 106. A perforated part, such as a housingcomponent 108, may be seated onto the apparatus 102, which acts as apositioning fixture to secure the perforated part in a particularlocation and orientation. The fabric press 104 is configured to securefabric 110 in a flattened state. The fabric press 104 may be used topress the fabric 110 onto the housing component 108 to stretch thefabric 110 over the housing component 108. The heating element 106 maybe placed over the fabric 110, which is stretched over the housingcomponent 108, to bond the fabric to the housing component 108. Inaspects, a layer of bonding material 112 (e.g., adhesive) can beincluded between the housing component 108 and the fabric 110. Theheating element 106 provides heat, through the fabric 110, to thebonding material 112 to activate the bonding material 112 and bond thefabric 110 to the housing component 108.

The apparatus 102 is formed as a substantial negative of the housingcomponent 108. In aspects, the apparatus 102 includes a body 114 and aplurality of protrusions 116 (e.g., pins, rods, cylinders)longitudinally extending from an outer surface 118 of the body 114 in anapproximate direction toward the fabric press 104 (e.g., a directionthat is (i) substantially parallel to a direction in which the fabric isto be stretched over the housing component 108, or (ii) substantiallynormal to the fabric 110 secured by the fabric press 104). The outersurface 118 has a contour that substantially matches a contour of aninterior surface of the perforated housing component 108 to enable theperforated housing component 108 to be seated, or mounted, onto theapparatus 102. The protrusions 116 are configured to be inserted througha plurality of holes (e.g., perforations) in the housing component 108.

The housing component 108 includes an exterior surface 120 having asubstantially planar region that defines a plane 122. The plane 122 maybe substantially parallel to the fabric 110 when the fabric 110 issecured by the fabric press 104 and when the housing component 108 isseated on the apparatus 102. For example, as illustrated in FIG. 1, theplane 122 is substantially tangential to a center point on a top surfaceof the housing component 108 that faces the fabric 110 in the fabricpress 104. As is described in more detail below with respect to FIG. 3,the substantially planar region may be on a side of the housingcomponent 108 that includes the holes and that faces the fabric in theassembly mechanism 100.

The fabric 110 may be any suitable fabric, such as a woven or knittextile. The fabric 110 may have some elasticity to enable the fabric tobe stretched over or around at least a portion of an object, such as theexterior surface 120 of the housing component 108. The fabric 110 may beformed to enable audio signals, such as audio output of a speakerdriver, to pass through the fabric 110. The fabric 110 may include oneor more colors and be formed with any suitable thickness. The techniquesdescribed herein reduce fabric dimpling, which is generallymore-predominantly visible in lighter and more-uniform colors.

FIG. 2A illustrates an example of the apparatus from FIG. 1. In theillustrated example, a zoomed-out view 200 is shown on the left side ofFIG. 2A and a zoomed-in view 202 is shown on the right side of FIG. 2A.As described above, the plurality of protrusions 116 protrude from theouter surface 118 of the body 114 of the apparatus 102. In the zoomed-inview 202, the protrusions 116 are shown as pins, rods, or cylinders,which extend from the outer surface 118 of the body 114. The protrusions116 may be formed using the same techniques as the body 114, such asinjection molding. A respective protrusion 116 may have a surface (e.g.,surface 204) that intersects a longitudinal axis 206 of the respectiveprotrusion 116 and is at an opposite end of the protrusion 116 from anend that is connected to the body 114 of the apparatus 102. In theillustrated example, the surface is substantially planar; however, thesurface 204 may alternatively be convex or concave. In one example, thesurface 204 of the protrusion 116 has a compound curvature, which may beoffset from the exterior surface 120 of the housing component 108 at aregion where the particular protrusion 116 is located when the housingcomponent 108 and the apparatus 102 are assembled together.Alternatively, the surface 204 of a particular protrusion 116 may besubstantially parallel to the exterior surface 120 of the housingcomponent 108 at the region corresponding to the particular protrusion116 when the apparatus 102 and the housing component 108 are assembledtogether. Also, the protrusions 116 may have differing longitudinallengths (e.g., length 208) relative to one another. For example, a firstsubset of protrusions in a first area of the apparatus 102 may have alongitudinal length that is different than a second subset ofprotrusions in a second, non-overlapping area of the apparatus 102.Further details are described with respect to FIG. 3.

FIG. 2B illustrates an example of the housing component from FIG. 1seated onto the apparatus from FIG. 1. In the illustrated example, azoomed-out view 210 is shown on the left side of FIG. 2 and a zoomed-inview 212 is shown on the right side of FIG. 2. The housing component 108is perforated such that it includes a plurality of openings (e.g., holes214), also referred to as perforations. For a speaker, audio waves cantravel through the holes 214 (e.g., audio waves originating internallyfrom a speaker driver of the speaker or originating externally from auser providing voice commands to the speaker). The number and size ofthe holes 214 in the housing component 108 may be a function of themaximum audio output for the speaker. The housing component 108 mayinclude a plastic material and be formed, for example, using plasticinjection molding techniques. However, any suitable material can be usedfor the housing component 108.

When the housing component 108 is seated onto the apparatus 102, theprotrusions 116 extend through the holes 214 from an interior surface(not shown in FIG. 2B) of the housing component 108 to the exteriorsurface 120 of the housing component 108. At least some of the holes 214in the housing component 108 may have different diameters relative toone another. Each of the protrusions 116 may be sized according to acorresponding hole 214 in the housing component 108 to enable theprotrusion 116 to extend through the hole 214. For example, to enablethe housing component 108 to easily seat onto the apparatus 102, arespective protrusion 116 may have a diameter that is approximately 0.5mm less than a diameter of a corresponding hole 214. The protrusions 116are configured to be proud (slightly protrude from a surface) relativeto the exterior surface 120 of the housing component 108. Accordingly,the longitudinal length (e.g., length 208) of a respective protrusion116 may be sufficient to project past the exterior surface 120 of thehousing component 108 by a predefined distance referred to as“proudness”. As further described in FIG. 3, the proudness may varybased on the geometry of the exterior surface 120 of the housingcomponent 108. In this way, the protrusions 116 of the apparatus 102support the fabric (e.g., fabric 110 from FIG. 1) when it is stretchedover the exterior surface 120 of the housing component 108, whichprevents the stretched fabric from sagging into the holes 214.

FIG. 3 illustrates an example of proudness variation in the apparatus102 from FIG. 1 when the housing component 108 from FIG. 1 is assembledor seated onto the apparatus 102. A side view 300 and a top perspectiveview 302 of the housing component 108 seated onto the apparatus 102 areillustrated. As above, when the housing component 108 is seated onto theapparatus 102, the protrusions extend through the holes 214 of thehousing component 108 from the interior surface of the housing component108 toward the exterior surface 120 of the housing component 108. Basedon the degree of curvature of the exterior surface 120 of the housingcomponent 108, the protrusions 116 may be substantially flush with theexterior surface 120 or proud relative to the exterior surface 120. Inregions where the exterior surface 120 of the housing component 108 hasa more-prominent curve (e.g., near edges and corners), the protrusions116 may have a greater relative proudness than other regions where theexterior surface 120 of the housing component 108 has a less-prominentcurve (e.g., in a central region). This greater proudness is to reducefabric dimpling that may otherwise occur in greater curvature regionshaving a support that is merely flush with the exterior surface 120.

In FIG. 3, section views 304, 306, and 308 of regions 310, 312, and 314,respectively, of the housing component 108 seated on the apparatus 102are illustrated. Comparatively, the protrusions 116 in the differentregions 310, 312, and 314 have different longitudinal lengths (e.g.,height), such that they project past the exterior surface 120 of thehousing component 108 by different predefined distances. The predefineddistance of a respective protrusion 116 is defined based on a degree ofcurvature of the exterior surface 120 of the housing component 108relative to the longitudinal axis 206 of the respective protrusion 116and within a region of the exterior surface 120 corresponding to therespective protrusion 116.

For example, in the section view 304, protrusions 116-1 project from theexterior surface 120 of the housing component 108 by a distance 316; insection view 306, protrusions 116-2 project from the exterior surface120 of the housing component 108 by a distance 318; and in section view308, protrusions 116-3 project from the exterior surface 120 of thehousing component 108 by a distance 320. The distances 316, 318, and 320of respective protrusions 116-1, 116-2, and 116-3 may be dependent onthe degree of curvature of the exterior surface 120 of the housingcomponent 108 at corresponding regions, in particular the degree ofcurvature relative to the plane 122.

For instance, the section view 306 is taken from a center region (e.g.,region 312) that is substantially parallel to the plane 122. The degreeof curvature of the exterior surface 120 of the housing component 108relative to the plane 122 is approximately zero in the region 312.Therefore, in substantially planar regions (e.g., the region 312), thedistance 318 may be small, such as within a range of approximately 0.0millimeters (mm) (e.g., flush with the exterior surface 120 of thehousing component 108) to approximately 0.03 mm.

The section view 308, taken from a region (e.g., region 314) near anedge of the housing component 108 that is curved about one axis, isillustrated with a plane 322, which is parallel to the plane 122. Thedegree of curvature of the exterior surface 120 of the housing component108 in the section view 308, relative to the plane 322, is larger thanthat of the section view 306. Correspondingly, the distance 320 (e.g.,proudness) of the protrusions 116-3 is greater near the edges of thehousing component 108 than the distance 318 of the protrusions 116-2near the center region of the housing component 108. An example of thedistance 320 used in moderate-curvature regions (e.g., the region 314)may be a distance within a range of approximately 0.11 mm toapproximately 0.17 mm. An example proudness of protrusions that are in aregion with a degree of curvature that is greater than that of thesection view 306 and less than that of the section view 308 (e.g., alow-curvature region) may be within a range of approximately 0.04 mm toapproximately 0.1 mm.

The section view 304, taken from a region (e.g., region 310) near acorner of the housing component 108 that is curved about two or moreaxes, is illustrated with a plane 324, which is parallel to the plane122. The degree of curvature of the exterior surface 120 of the housingcomponent 108 in the section view 304, relative to the plane 324, islarger than that of the section view 308. Consequently, the distance 316of the protrusions 116-1 is greater than the distance 320 and thedistance 318. An example of the distance 316 used in high-curvatureregions (e.g., the region 310) may be within a range of approximately0.17 mm to approximately 0.23 mm.

Accordingly, each protrusion 116 is formed relative to the housingcomponent 108, such that the protrusion 116 has some dimensions (e.g.,longitudinal length, three-dimensional orientation of the planar surface204) that are defined relative to the exterior surface 118 of thehousing component 108 and some other dimensions (e.g., diameter,longitudinal direction) defined relative to a corresponding hole 214 inthe housing component 108. The longitudinal direction may also besubstantially normal to the plane 122 to support the fabric as thefabric is stretched over the housing component 108 in a direction normalto the plane 122.

The differing proudness (distances 316, 318, and 320) of the protrusions116 relative to the exterior surface 120 of the housing component 108supports the fabric, when the fabric is stretched over the housingcomponent 108, over different degrees of curvature of the exteriorsurface 120 of the housing component 108. Regions with a greater degreeof curvature allow the fabric to stretch a greater distance, therebyincreasing the tensile forces in the fabric as it is forced against thehousing component 108. Normal forces between the fabric and the housingcomponent 108 are also increased in regions with greater curvature,which results in more-prominent fabric dimpling (e.g., sagging into theholes). The greater proudness of the protrusions 116 supports thesegreater normal forces in the fabric and prevent the fabric fromdimpling.

FIG. 4 illustrates a section view 400 of an example implementation ofthe assembly mechanism 100 from FIG. 1, where the heating element 106 isplaced onto the fabric 110, which is stretched over the housingcomponent 108 seated on the apparatus 102. In addition, FIG. 4illustrates a zoomed-in view 402 of a portion of the section view 400.As illustrated, the protrusion 116 supports the fabric 110 that isstretched over the housing component 108. The heating element 106 mayinclude any suitable material for conducting heat, including a coppermaterial. A layer of protective material 404, such as silicone or othernon-stick material, may be positioned between the heating element 106and the fabric 110 to prevent the fabric 110 from adhering to theheating element 106 or to prevent the heating element 106 from damagingthe fabric 110. A layer of bonding material 112 (not shown in FIG. 4)may be positioned between the fabric 110 and the housing component 108.

The bonding material 112 may include any suitable bonding material, suchas an adhesive (e.g., spray adhesive, adhesive tape, liquid adhesive,etc.). The bonding material 112 may be applied to the housing component108 prior to stretching the fabric 110 over the housing component 108 toenable the bonding material 112 to dry. If the bonding material 112 iswet at the time of stretching the fabric 110 over the housing component108, it may hinder the stretching of the fabric 110.

Example Methods

FIG. 5 depicts a method 500 of reducing fabric dimpling in electronicdevices, in particular speaker housings, and associated apparatuses. Themethod 500 is shown as a set of blocks that specify operations performedbut are not necessarily limited to the order or combinations shown forperforming the operations by the respective blocks. Further, any of oneor more of the operations may be repeated, combined, reorganized, orlinked to provide a wide array of additional and/or alternate methods.In portions of the following discussion, reference may be made to theexample assembly mechanism 100 of FIG. 1 or to entities or processes asdetailed in FIGS. 2-4, reference to which is made for example only. Thetechniques are not limited to performance by one entity or multipleentities operating on one device.

At 502, a perforated housing component is assembled onto an apparatusincluding a plurality of protrusions configured to be inserted into aplurality of holes in an interior surface of the perforated housingcomponent and to extend past an exterior surface of the perforatedhousing component by different predefined distances relative to oneanother. The perforated housing component may be the housing component108 from FIG. 1. The apparatus may be the apparatus 102 from FIG. 1 andmay be formed as a negative of the perforated housing component. Theplurality of protrusions (e.g., the protrusions 116) extend through theplurality of holes to project from the exterior surface (e.g., theexterior surface 120 of the housing component 108) of the perforatedhousing component by a predefined distance. The predefined distance(e.g., the predefined distance 316, 318, or 320) of a respectiveprotrusion is defined based on a degree of curvature of the exteriorsurface of the perforated housing component relative to a longitudinalaxis (e.g., the longitudinal axis 206 of the protrusion 116) of therespective protrusion and within a region of the exterior surface of theperforated housing component corresponding to the respective protrusion.Assembling the perforated housing component onto the apparatus causes afirst subset of the protrusions to extend past the exterior surface ofthe perforated housing component by a first distance, and a secondsubset of the protrusions to extend past the exterior surface of theperforated housing component by a second distance that is different thanthe first distance.

At 504 and subsequent to the perforated housing component beingassembled onto the apparatus, fabric is stretched over the exteriorsurface of the perforated housing component and the plurality ofprotrusions projecting from the exterior surface of the perforatedhousing component. The fabric may be the fabric 110 from FIG. 1, whichis secured by the fabric press 104 of the assembly mechanism 100 andpressed onto the exterior surface 120 of the housing component 108. Theprotrusions 116 on the apparatus 102 support the fabric 110 fromdimpling into the holes 214 of the perforated housing component.

At 506, the stretched fabric is bonded to the housing component. Inaspects, the stretched fabric is bonded to the housing component byapplying heat, while the perforated housing component is seated on theapparatus, to a bonding material positioned between the fabric and theperforated housing component to adhere the fabric to the perforatedhousing component. For example, after stretching the fabric 110 over thehousing component 108, the heating element 106 is placed over the fabric110 to apply heat, through the fabric 110, to the bonding material 112.The heat activates (e.g., by melting) the bonding material 112 to bondthe fabric 110 to the exterior surface 120 of the housing component 108.Subsequent to bonding the fabric 110 to the housing component 108, theheating element 106 may be removed from fabric 110.

At 508, the housing component is removed from the apparatus. Forexample, subsequent to bonding the fabric 110 to the housing component108, the protrusions 116 may be removed from the holes 214 in thehousing component 108 (e.g., the housing component 108 may be unseatedfrom the apparatus 102).

Example Devices

FIG. 6 illustrates example devices for which the apparatus for reducingfabric dimpling can be implemented. For instance, the apparatus 102 fromFIG. 1 can be used to reduce or prevent fabric dimpling from occurringduring assembly of speakers, such as electronic speaker devices 602. Theelectronic speaker devices 602 include a housing (e.g., the housingcomponent 108) wrapped in fabric (e.g., the fabric 110). The fabrichides perforations in the housing component, through which audio wavescan travel. The electronic speaker device 602 can include any suitablegeometry. Some example electronic speaker devices include a 360° outputspeaker 602-1, a longitudinally-vertical box speaker 602-2, asubstantial prolate-spheroid-shaped speaker 602-3, a substantialoblate-spheroid-shaped speaker 602-4, and a longitudinally-horizontalbox speaker 602-5. Using the techniques described herein (e.g., theapparatus 102 of FIG. 1), fabric dimpling in the fabric 110 wrapped overthe housing component 108 of the electronic speaker devices 602 isreduced.

What is claimed is:
 1. A method for reducing fabric dimpling, the methodcomprising: assembling a perforated housing component onto an apparatusincluding a plurality of protrusions configured to be inserted into aplurality of holes in an interior surface of the perforated housingcomponent and to extend past an exterior surface of the perforatedhousing component, a predefined distance between the exterior surfaceand a respective protrusion defined based on a degree of curvature ofthe exterior surface of the perforated housing component within a regionof the exterior surface of the perforated housing componentcorresponding to the respective protrusion; subsequent to the perforatedhousing component being assembled onto the apparatus, stretching fabricover the exterior surface of the perforated housing component and theplurality of protrusions projecting from the exterior surface of theperforated housing component; bonding the stretched fabric to thehousing component; and removing the housing component from theapparatus.
 2. The method as recited in claim 1, wherein assembling theperforated housing component onto the apparatus causes: a first subsetof the plurality of protrusions to extend past the exterior surface ofthe perforated housing component by a first distance; and a secondsubset of the plurality of protrusions to extend past the exteriorsurface of the perforated housing component by a second distance that isdifferent than the first distance.
 3. The method as recited in claim 2,wherein assembling the perforated housing component onto the apparatusfurther causes: at least a third subset of the plurality of protrusionsto extend past the exterior surface of the perforated housing componentby a third distance that is different than the first and seconddistances.
 4. The method as recited in claim 1, wherein the plurality ofprotrusions project from the exterior surface of the perforated housingcomponent by a greater distance at corner regions of the perforatedhousing component than at a center region of the perforated housingcomponent.
 5. The method as recited in claim 1, wherein the protrusionsare configured to support the fabric when the fabric is stretched overthe exterior surface of the perforated housing component.
 6. The methodas recited in claim 1, wherein the bonding comprises applying heat to abonding material positioned between the fabric and the perforatedhousing component to adhere the fabric to the perforated housingcomponent.
 7. The method as recited in claim 6, wherein the bondingmaterial is dry when stretching the fabric over the exterior surface ofthe perforated housing component and the plurality of protrusionsprojecting from the exterior surface of the perforated housingcomponent.
 8. The method as recited in claim 6, wherein the bondingmaterial is a spray adhesive.
 9. The method as recited in claim 1,wherein the plurality of protrusions extend longitudinally in a firstdirection that is substantially parallel to a second direction in whichthe fabric is assembled to the exterior surface of the perforatedhousing component.
 10. An apparatus configured to reduce fabric dimplingin fabric that is stretched over a perforated housing component, theapparatus comprising: a body having an outer surface, the bodyconfigured to support the perforated housing component for assembly ofthe fabric onto an exterior surface of the perforated housing component;and a plurality of protrusions longitudinally extending from the outersurface of the body in a first direction that is substantially parallelto a second direction in which the fabric traveling on a fabric press ispressed onto the the perforated housing component that is supported bythe body, the plurality of protrusions configured to be inserted into aplurality of holes in the interior surface of the perforated housingcomponent and project past the exterior surface of the perforatedhousing component to support the fabric as the fabric is stretched overthe perforated housing component, a first subset of protrusions of theplurality of protrusions being located in a central region of the bodythat is substantially planar, a second subset of protrusions of theplurality of protrusions being located proximate to a periphery of thebody that is curved and having greater longitudinal lengths than thoseof the first subset of protrusions, and a respective protrusion of theplurality of protrusions having a longitudinal length sufficient toproject past the exterior surface of the perforated housing component bya predefined distance that is defined based on a degree of curvature ofthe exterior surface of the perforated housing component within a regionof the exterior surface of the perforated housing componentcorresponding to the respective protrusion.
 11. The apparatus as recitedin claim 10, wherein the predefined distance of the respectiveprotrusion of the plurality of protrusions is defined to prevent thefabric from sagging into a corresponding hole of the plurality of holeswhen the fabric is stretched over the exterior surface of the housingcomponent.
 12. The apparatus as recited in claim 10, wherein: the firstsubset of protrusions project past the exterior surface of theperforated housing component by a first distance when the perforatedhousing component and the apparatus are assembled together; the secondsubset of protrusions extend past the exterior surface of the perforatedhousing component by a second distance when the perforated housingcomponent and the apparatus are assembled together; and the seconddistance is different than the first distance.
 13. The apparatus asrecited in claim 12, wherein: the first distance is correlated to thecurvature of the exterior surface of the perforated housing component ata first region corresponding to the first subset of protrusions; thesecond distance is correlated to the curvature of the exterior surfaceof the perforated housing component at a second region corresponding tothe second subset of protrusions; and the second distance is greaterthan the first distance based on the exterior surface of the perforatedhousing component having a greater degree of curvature at the secondregion in comparison to another degree of curvature at the first region.14. The apparatus as recited in claim 10, wherein the plurality ofprotrusions project past the exterior surface of the perforated housingcomponent by different predefined distances when the perforated housingcomponent and the apparatus are assembled together, and wherein thedifferent predefined distances include greater distances at cornerregions of the perforated housing component in comparison to a centerregion of the perforated housing component.
 15. The apparatus as recitedin claim 10, wherein the longitudinal length of the respectiveprotrusion is defined to have a proudness relative to the exteriorsurface of the perforated housing component that: is within a firstrange of approximately 0.0 millimeters to 0.03 millimeters insubstantially planar regions of the perforated housing component; iswithin a second range of approximately 0.04 millimeters to approximately0.1 millimeters in low-curvature regions of the perforated housingcomponent; is within a third range of approximately 0.11 millimeters toapproximately 0.17 millimeters in moderate-curvature regions of theperforated housing component; and is within a fourth range ofapproximately 0.17 millimeters to approximately 0.23 millimeters inhigh-curvature regions of the perforated housing component.
 16. Theapparatus as recited in claim 10, wherein at least some protrusions ofthe plurality of protrusions have a diameter of approximately 4.0millimeters.
 17. The apparatus as recited in claim 10, wherein therespective protrusion has: a first end that is connected to the body;and a second end opposite the first end and having a surface that has acompound curvature that is offset from the exterior surface of theperforated housing component at the region corresponding to therespective protrusion.
 18. The apparatus as recited in claim 17, whereinthe second end is configured to support the fabric when the fabric isstretched over the exterior surface of the perforated housing component.19. The apparatus as recited in claim 10, wherein the body and theplurality of protrusions are formed using injection molding.
 20. Theapparatus as recited in claim 10, wherein: the plurality of protrusionsincludes a third subset of protrusions located proximate to an edgeregion of the body; and the third subset of protrusions have respectivelongitudinal lengths that are greater than those of the first subset ofprotrusions and less than those of the second subset of protrusions.